US6450409B1 - Method and apparatus for wiring room thermostat to two stage HVAC system - Google Patents
Method and apparatus for wiring room thermostat to two stage HVAC system Download PDFInfo
- Publication number
- US6450409B1 US6450409B1 US09/714,029 US71402900A US6450409B1 US 6450409 B1 US6450409 B1 US 6450409B1 US 71402900 A US71402900 A US 71402900A US 6450409 B1 US6450409 B1 US 6450409B1
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- Prior art keywords
- stage
- control
- microcontroller
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- diode
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/1906—Control of temperature characterised by the use of electric means using an analogue comparing device
- G05D23/1912—Control of temperature characterised by the use of electric means using an analogue comparing device whose output amplitude can take more than two discrete values
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/50—Control or safety arrangements characterised by user interfaces or communication
- F24F11/52—Indication arrangements, e.g. displays
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
- F24F11/63—Electronic processing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/70—Control systems characterised by their outputs; Constructional details thereof
- F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
- F24F11/86—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling compressors within refrigeration or heat pump circuits
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/88—Electrical aspects, e.g. circuits
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F2110/00—Control inputs relating to air properties
- F24F2110/10—Temperature
Definitions
- HVAC heating, ventilating and air conditioning
- staged HVAC equipment is ever increasing.
- a typical two stage system has a low and a high mode of heat transfer.
- two stage gas furnaces have allowed the use of low and high combustion for many years.
- Two stage systems have advantages over the typical single stage system. Firstly, greater comfort is allowed. By allowing a lower heat transfer mode when the heat load is lower in the home, the temperature essentially will not swing beyond the desired set point in contrast to a single stage system. Furthermore, during the low transfer mode the system is more likely to run longer which helps to eliminate stagnant air conditions. Secondly, greater efficiency is obtained by using a low transfer mode. That is, less energy is consumed since the need for the high transfer mode only occurs for a small percentage of the time.
- a single control wire such as an existing control wire to a room thermostat, can be used to select both the high and low heat transfer modes of operation of a two stage HVAC system.
- the control to be used in a two stage system has a power supply from a transformer, such as a 24 VAC transformer. This voltage is full wave rectified to create DC voltages for the control's microcontroller and relays.
- the microcontroller based control determines if an input is “ON” or “OFF” by looking at the phase relationships of the control signal. Additional information is provided on the single control wire by placing a diode in series with the signal. The diode is added to create a distinct signal recognizable by the microcontroller.
- FIGS. 1 a - 1 c taken together constitute a schematic of a control for use with a two stage cooling system with which the invention is used;
- FIG. 2 shows typical “ON” and “OFF” signals
- FIGS. 3-5 show a single wire operating mode with Y 1 and Y 2 active, Y 1 only active and Y 1 and Y 2 off, respectively;
- FIG. 6 is a schematic diagram of a typical two stage room thermostat shown with the Y 1 signal line connected to the Y 2 signal line through a diode in accordance with the invention.
- FIGS.1 a - 1 c operation of the preferred embodiment of the invention will be described.
- power 24 VAC
- QC 1 signal 24 VAC
- QC 2 signal C or earth ground
- Fuse F 1 is a 3 amp automotive style (ATO) and is attached to fuse terminals FT 1 and FT 2 serially connected to the 24 VAC power.
- Fuse Fl protects the circuitry of the control by limiting the current to the device.
- Capacitor C 8 and metal oxide varistor M 1 act as a noise filter for the 24 VAC power.
- Fuse F 1 is connected to the signal 24 VAC and the anode of diode D 2 and the cathode of diode D 1 .
- the anode of diode D 3 and the cathode of diode D 4 are connected to the C signal. These four diodes rectify the 24 VAC power to a DC power source 24 _RECT (cathodes of D 2 and D 3 ) and GND (anodes of D 4 and D 1 ). This is the power source for all the electronics of the control.
- the anode of diode D 6 is also connected to the signal 24 _RECT.
- the cathode of diode D 6 is connected to signal RLAY_PWR.
- Capacitors C 10 and C 5 are connected between signal RLAY_PWR and GND. These capacitors act to filter noise from the RLAY_PWR signal and to limit voltage change when loads are energized on RLAY_PWR.
- Signal RLAY_PWR is the power source for all the relays of the assembly (K 1 -K 3 ).
- the anode of light emitting diode LED 3 is connected RLAY_PWR and the cathode of light emitting diode LED 3 is serially connected to resistor R 1 .
- the other side of resistor R 1 is attached to GND. This causes light emitting diode LED 3 to be illuminated when power is applied to the control.
- the anode of diode D 5 is connected to 24 _RECT and the cathode is connected to 24LOGIC.
- Diode D 5 acts to isolate filter capacitor C 4 (attached to 24LOGIC and GND) from RLAY_PWR.
- Capacitor C 4 filters the rectified DC power.
- One side of resistor R 9 is attached to 24LOGIC while the other side of the resistor is connected to the cathode of zener diode Z 1 .
- the anode of zener Z 1 is connected to GND.
- Resistor R 15 is connected across the zener Z 1 to discharge capacitor C 4 during power interruption.
- Resistor R 9 limits current flow to the zener diode while the zener regulates 24LOGIC to five volts DC (VDD).
- Capacitors C 9 and C 2 act to filter the five volt DC power. Resistor R 15 also discharges capacitors C 9 and C 2 during power interruption.
- the oscillator for the microcontroller U 1 comprises resistor R 12 and the internal oscillator circuitry of the microcontroller. Pins 1 and 2 of microcontroller U 1 are connected to respective opposite sides of resistor R 12 . Resistor R 12 sets the frequency of operation of the microcontroller (typically 2.73 MHz). Signal +5V is connected to resistor R 8 . The other side of resistor R 8 is attached to pin 20 (RESET') and one side of capacitor C 7 . The second pin of capacitor C 7 is connected to GND. This RC circuit maintains the RESET' signal at a low logic level until +5V power has stabilized after a power cycle.
- Resistor R 10 is connected to C and the interrupt pin of the microcontroller U 1 pin 19 (signal IRQ').
- Capacitor C 6 is connected between IRQ' and GND and acts to filter the IRQ' signal.
- IRQ' is also connected to U 1 pin 18 to utilize the internal protection diodes on this pin to protect the microcontroller from excessive voltage.
- Resistor R 11 is also connected across capacitor C 6 and acts to discharge capacitor C 6 during power interruption.
- Signal IRQ' is a 5 volt DC, 60 Hz square wave (with 60 Hz, 24 VAC applied to the control). This signal forms the time base for all operations of the microcontroller.
- Signal Y 1 is generated by the room thermostat when the temperature rises one degree above the set point.
- Signal Y 1 is input to the control via quick connect QC 8 .
- Signal Y 1 is connected to one side of resistor R 2 .
- the other side of resistor R 2 is connected to C (or Common).
- Capacitor Cl 2 is connected in parallel across resistor R 2 to filter noise signals from signal Y 1 .
- Signal Y 1 is connected to the anode of zener Z 4 .
- the cathode of zener Z 4 is serially connected to the cathode of zener Z 5 , while the anode of zener Z 5 is attached to the input diodes of U 3 B, an opto-isolator.
- the other side of the input diodes is connected to resistor R 13 , in turn connected to common (signal C).
- This network created by zeners Z 4 , Z 5 , the input diodes of opto-isolator U 3 B, and resistor R 13 forms a voltage discriminator network such that opto-isolator U 3 B will not be energized unless signal Y 1 is above 12 volts AC.
- the output portion of opto-isolator U 3 B consists of an isolated transistor. The transistor's collector is connected to +5V. The emitter of the transistor is connected to signal Y 1 _IN (pin 7 of U 1 ). Resistor R 4 is placed between Y 1 _IN and GND to act as a pull-down.
- Y 1 _IN will be energized at a 120 Hz rate whenever an AC signal is applied to Y 1 with respect to C (common).
- the opto-isolator allows the micro-controller to detect the frequency and phase of the incoming signal regardless of its source.
- Signal Y 2 is generated by the room thermostat when the temperature rises typically three to five degrees above the set point.
- Signal Y 2 is input to the control via quick connect QC 7 .
- Y 2 is connected to resistor R 3 with the other side of resistor R 3 connected to C (or Common).
- Capacitor C 11 is connected in parallel across resistor R 3 to filter noise signals from signal Y 2 .
- Signal Y 2 is connected to the anode of zener Z 2 .
- the cathode of zener Z 2 is serially connected to the cathode of zener Z 3 , while the anode of zener Z 3 is attached to the input diodes of opto-isolator U 3 A.
- the other side of the input diodes is connected to resistor R 14 , in turn connected to common.
- This network created by zeners Z 2 , Z 3 , the input diodes of opto-isolator U 3 A, and resistor R 14 forms a voltage discriminator network such that opto-isolator U 3 A will not be energized unless signal Y 2 is above 12 volts AC.
- the output portion of opto-isolator U 3 A consists of an isolated transistor. The transistor's collector is connected to +5V. The emitter of the transistor is connected to signal Y 2 _IN (pin 5 of U 1 ). Resistor R 5 is placed between Y 2 _IN and GND to act as a pull-down.
- Y 2 _IN will be energized at a 120 Hz rate whenever an AC signal is applied to Y 2 with respect to C (common).
- the opto-isolator allows the micro-controller to detect the frequency and phase of the incoming signal regardless of its source.
- QC 10 and QC 9 act as a “TEST” input to the microcontroller.
- QC 10 is connected to 24 VAC.
- QC 9 is attached to resistor R 7 with the other pin of resistor R 7 applied to GND.
- QC 9 is also attached to resistor R 16 with the other side of resistor R 16 applied to pin 3 of microcontroller U 1 , signal TEST_IN.
- the microcontroller can detect the presence of the short. The s/w in the microcontroller will reset all time delays when this occurs. Thus, an installer or service person may circumvent the antishort cycle delays with this input.
- Pin 15 of microcontroller U 1 (signal COND_FAN) is connected to relay driver U 2 A.
- the output of U 2 A is connected to one side of the K 3 relay coil (see FIG. 1 c ).
- the other side of the K 3 relay coil is connected to RLAY_PWR.
- the common terminal K 3 is connected to L 1 , the 240 VAC source (quick connect QC 6 ).
- the normally open terminal of relay K 3 is connected to quick connect QC 5 . This is attached in the system to the condenser fan motor, which circulates air over the condenser coils.
- microcontroller U 1 is able to control the COND_FAN (condenser fan motor) of the air conditioner.
- Pin 13 of microcontroller U 1 (signal COMP_PW) is connected to relay driver U 2 C.
- the output of U 2 C is connected to one side of the K 1 relay coil (see FIG. 1 c ).
- the other side of the K 1 relay coil is connected to RLAY_PWR.
- the common terminal of relay K 1 is connected to the 24 VAC source.
- the normally open terminal of relay K 1 is also connected to the common terminal of relay K 2 . This allows 24 VAC to be connected to relay K 2 when relay K 1 is energized.
- Pin 14 of microcontroller U 1 (signal COMP_SPD) is connected to relay driver U 2 B.
- the output of relay driver U 2 B is connected to one side of the K 2 relay coil (FIG. 1 c ).
- the other side of the K 2 relay coil is connected to RLAY_PWR.
- the normally open terminal of relay K 2 is connected to QC 4 (signal HIGH).
- the normally closed contact of relay K 2 if connected to QC 3 (signal LOW).
- the signals HIGH and LOW are connected to the coils of two contactors in the system, which energize the forward or reverse rotation direction of a two stage compressor.
- microcontroller U 1 is able to control the two stage compressor and the rotation that the motor operates through energizing relay K 1 and (or) relay K 2 .
- the other sides of the contactor coils are attached to Common (signal C).
- Capacitors C 13 and C 14 are placed across the respective output signals LOW and HIGH to suppress electrical noise.
- the pin of U 2 :H is the common terminal for the suppression diodes internal to the relay driver. And is connected to RLAY_PWR to insure that electrical transient voltage spikes (also known as back electromotive force) will be suppressed when each relay is de-energized by the microcontroller U 1 .
- Pin 16 of microcontroller U 1 (signal HI_LED_DRV) is connected to the cathode of the light emitting diode LED 2 .
- the anode of diode LED 2 is connected to resistor R 6 (and the anode of diode LED 1 ), while the other side of resistor R 6 is attached to VDD. Resistor R 6 limits current flow through the light emitting diode. This enables microcontroller U 1 to control diode LED 2 to indicate when the control is operating in HIGH (capacity) mode.
- Pin 17 of microcontroller U 1 (signal LOW_LED_DRV) is connected to the cathode of the light emitting diode LED 1 .
- the anode of diode LED 1 is connected to resistor R 6 (and the anode of LED 2 ), while the other side of resistor R 6 is attached to VDD. Resistor R 6 limits current flow through the light emitting diode. This enables microcontroller U 1 to control diode LED 1 to indicate when the control is operating in LOW (capacity) mode.
- the microcontroller based control determines if an input is “ON” or “OFF” by looking at the phase relationships of the control signal. Typical “ON” and “OFF” signals are shown in FIG. 2 . The addition of information to this signal can be accomplished by placing a diode in series with the signal, the resulting signal shown in FIG. 3 . It will be seen that these signal conditions “OFF”, “ON” and “Diode in Series” are very different from one another and can be easily detected by the microcontroller.
- FIG. 6 shows the schematic diagram of a typical two stage room thermostat 12 shown with the addition of a diode CR 1 .
- the anode of this diode is connected to signal line Y 1 and the cathode is connected to signal line Y 2 .
- Room thermostat 12 includes a fan switch 14 and system switch 16 interconnected with heat anticipators H 1 , H 2 and cool anticipators C 1 , C 2 .
- RH and RC terminals are for connection to an indoor and outdoor unit, respectively.
- Terminals W 1 and W 2 are for connection to first and second heat stages, respectively.
- Y 1 and Y 2 terminals are for connection with first and second cool stages.
- signal lines W 1 and W 2 can be interconnected in like manner by adding therebetween another diode.
- This control has two main purposes.
- the first purpose is to reduce the number of wires required to operate and control a two stage air conditioning condenser unit.
- Opto-isolators U 3 A and U 3 B allow the control in the condenser unit to be powered from a separate 24 VAC power source (inside the condenser unit) from the indoor fan control 24 VAC power supply. This is very important if the condenser unit is to be used as a replacement for an existing outdoor unit because the control is insensitive to the phase relationships between the two power supplies.
- the second purpose (or mode of operation) is to operate with two stage room thermostats which have additional wiring available. These modes of operation are described below. Thus the control can universally control two stage condenser units.
- QC 7 (signal Y 2 ) and QC 8 (signal Y 1 ) are shorted together via a wire lead attached to the control (see dashed line 10 in FIG. 1 a ). This point then is connected to the Y 1 signal from the room thermostat as shown in FIG. 4 .
- this mode only one control wire is available from the room thermostat to the condensing unit.
- diode CR 1 in the room thermostat half wave rectifies the signal from the room thermostat.
- the microcontroller U 1 via inputs, Y 1 _IN (pin 7 ) and Y 2 _lN (pin 5 ) then detects this half wave signal.
- the condenser fan is energized (through relay K 3 ) and the LOW capacity of operation is selected (by de-energizing relay K 2 ). Then relay K 1 is energized to power the low capacity contactor, which will apply the power to the compressor in a manner to select proper shaft rotation sense for low capacity operation. Notably, the proper capacity is selected (via relay K 2 ) before the contactors are powered (via relay K 1 ).
- a full wave AC signal will be applied to the Y 1 terminal of the control. This in turn, causes a full wave rectified signal (through optos U 3 A and U 3 B) to be applied to the microcontroller U 1 at signals Y 1 _IN and Y 2 _IN. If the microcontroller detects this condition, the condenser fan is energized (through relay K 3 ) and the HIGH capacity of operation is selected (by energizing relay K 2 ). Then relay K 1 is energized to power the high capacity contactor, which will apply the power to the compressor in a manner to select proper shaft rotation sense for high capacity operation. Notably, if the compressor has been operating in LOW capacity the microcontroller will delay energizing relay K 1 to allow the pressure to equalize in the refrigerant system. This insures that the compressor will not attempt to start against a high pressure condition.
- QC 7 (signal Y 2 ) and QC 8 (signal Y 1 ) are not shorted together.
- the control is intended to be used with a standard two stage room thermostat with separate control wires for first and second stage of operation, i.e., without diode CR 1 . If the room thermostat calls for the first stage (LOW capacity) of cooling, a signal will only appear on Y 1 . If the room thermostat calls for two stages of cooling (HIGH capacity), then both Y 1 and Y 2 will be energized.
- the microcontroller can accommodate mis-wire conditions on Y 1 and Y 2 by sensing the presence of only one signal at Y 1 _IN and Y 2 _IN.
- the condenser fan is energized (through relay K 3 ) and the low capacity of operation is selected (by de-energizing relay K 2 ).
- relay K 1 is energized to power the low capacity contactor, which will apply the power to the compressor selecting the proper shaft rotation sense (direction) for low capacity operation.
- a full wave AC signal will be applied to the Y 1 terminal of the control. This in turn, causes a full wave rectified signal (through optos U 3 A and U 3 B) to be applied to microcontroller U 1 at signals Y 1 _IN and Y 2 _IN. If the microcontroller detects this condition, the condenser fan is energized (through relay K 3 ) and the HIGH capacity of operation is selected (by energizing relay K 2 ). Then relay K 1 is energized to power the high capacity contactor which will apply the power to the compressor selecting the proper shaft rotation sense (direction) for high capacity operation. As before (in mode 1), if the LOW capacity has been energized, the microcontroller will delay energizing the compressor in High capacity to allow the pressure to equalize. Notably, the HIGH capacity operation is the same for both mode 1 and 2 conditions.
- a control made as shown in FIGS. 1 a - 1 d comprised the following components:
- PCB Printed Circuit Board
- Vert Fuse Terminal (FT 1 , FT 2 )
- Resistors 10K, 1/4W,1% (R 1 , R 17 )
- Zener 1N5231, 5%, 0.5W (Z 1 )
- Zener 1N5242, 5%, 0.5W (Z 2 , Z 3 , Z 4 , Z 5 )
- Resistors 100K, 1/8W, 5% (R 10 , R 11 , R 16 )
- Capacitors 0.01uF, 50V (C 6 , C 11 , C 12 , C 15 )
- Capacitors 0.1uF, 50V (C 7 , C 9 )
- Capacitors 100uF, 50V ELECTL RAD CAPS (C 10 )
- Capacitors 0.1uF, 100V FILM CAP, 20% (C 5 , C 8 , C 13 , C 14 )
Abstract
Description
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US09/714,029 US6450409B1 (en) | 2000-04-14 | 2000-11-15 | Method and apparatus for wiring room thermostat to two stage HVAC system |
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US19711400P | 2000-04-14 | 2000-04-14 | |
US09/714,029 US6450409B1 (en) | 2000-04-14 | 2000-11-15 | Method and apparatus for wiring room thermostat to two stage HVAC system |
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US09/714,029 Expired - Fee Related US6450409B1 (en) | 2000-04-14 | 2000-11-15 | Method and apparatus for wiring room thermostat to two stage HVAC system |
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